Method of molding sound-records and other objects.



-lt l@i JONAS W. AYLSWOBTH, 0F EhST GRANGE, NEW JERSEY, ASSIGNQR, BY MESNE ASSIGN- MENTS, '10 NEW JERSEY PATENT COMPANY, 8F WEST ORANGE, NEWJERSEY, A I CORPORATION OF NEW JERSEY. I

names or nonnrnh sounn-nnco s nnn ornnn ona'nc'rs;'

Specification of Icttcrs Patent. Patented J 113, 1915',

No Drawing. Original application filed August as, 1910, Serial No. 579,130. Divided and this application of East Orange, in the county of Essex and '5 State of New Jersey, have invented a certain new .and' useful Method of Molding Sound-Records and other Objects, of which the following is a description.

My invention relates to a process of molding sound records and other objects, the

process involving the formation of a surphenolic condensation face layer of a hard final infusible insoluble product upon the object. v

This application is a division of my application Serial Nb. 579,130, filed August 26,

1910 for Process of molding sound records and other objects- In an application filed by me on August 26, 1910, Serial No. 579,129, entitled Method of molding objects having a refractory sur face layer, upon which application U. S. Patent No.,1,094,828 has been granted, I have described a method of molding scund records and other objects by-coating the sur faceof a mold with a solution of ingredients, which, uponbeing heated, form. a surface layer or veneer. on the mold surface of a hard 'infusible insoluble phenolic condensation product having the mold impremion formed on the outer surface thereof. The object to be surfaced is pressed into contact with this hardened veneer in the mold, with application of heat suflicient to cause the object or mass and the surface layer to become firmly Welded together, the molded object then being cooledand removed from the mold with the surface layer adhering thereto. The process claimed herein is in some instances an improvement upon the process described in my application above-referred to, and is in some aspects a specific embodiment thereof My present process will be described in connection with sound records, although it will be obvious that it may be applied to the formation of other molded. objects with.

equally good results V A blank mold surface is painted with or dipped in a solution of a. fusible solublephenolic condensation product and a hardennee Itovember a, 1910. Serial no. sconce tetraemin, in a suitable solvent which may be either a volatile solvent, such as amyl alcohol, or a solid solvent, such as mononitro-naphthalene, oil of mirbane, (ll-nitrobeqnol, and other solvents referred to in my application Serial No. 579,129, filed August 26, 1910. This coating upon the matrix may be the enamel lacquer or varnish described in my application Serial No. 543,239, filed February 11, 1910, as stated in my applica tionSerial No. '579,1 219, filed August 26, 19104 above referred to, and upon which 'U.

Patent No. 1,098,608 has been granted.- The solvent used should be one Whose-boiling point is higher than the temperature at which it is desired. to perform the final hardening reaction'of the substance, in solution into a refractory insoluble infusible condensation product.v

Having coated theblank mold, the sam is dried, and heated sufficiently to cause the ingredients of the coating to react to form ,1

the final infusible insoluble refractory product referred to.v A blank phonograph rec- 0rd, which is preferably made of a phenolic condensation product vor a mixture of the same with an inert fillin material, is then pressed in the blank mol into contact with the surfacing layer formed in the blank mold as described, heat being applied suliiciently to cause the Welding of the surface layer to the blank, and thetransfer of the surface layer from the blankmold-to the blank upon the cooling and withdrawal of the blank from the mold. The final hardening ofthe surface layer or varnish in the blank mold may be im a'rted to the same at the same time that the Y lank is expanded into contact therewith and Welded thereto, it

only-being necessary to dry the surface coat in the blank mold before pressing the blank into contact therewith, with application of heat sufiici'ent to cause the final reaction of the surface layer and. the welding of the same to the blank. The blank record thus the surface layer of the blankand'the pres ence therein of a plasticity component, such as described in my application Serial. No

496,060, the record is formed in thesurface thereof by the matrix in much thesame manner that the sound record is impressed upon a heated celluloid blank pressed into a mold. The record thus formed is cooled and Withdrawn from the mold.

The process thus described is an extremely cheap and'practical method of manufacture,

because of the comparative cheapness of the,

blank molds in which the surface veneer is formed. i v

. Having now described my invention-,what I claim and desire to protect by Letters .Patent is as follows 1 1. The process of molding sound which consists :in coating a blank matrix witha' solution of substances which react upon application of heat to form a final hardened phenolic condensation product which is infusible and insoluble but 'Sllflik ciently plastic when heated to take a record and pre'ssing the blank thus formed .into a.

- recordmold with suflicientapplication of heat to cause the sound record to be formed described. 4. v 2. Theprocess of molding soundrecords which-consists in. forming upon a blank matrix a'coating of substances, including'a sol'i'dsolvent plasticity element, which coating is adapted to be transformed chemically by heatinto an infusibleinsoluble phenolic condensation product, which becomes sufiiciently plastic on subseqnentapplicat ion of heat to receive a record impression, drying the coating, pressing ablank into contact with the coatingrvith' application'of Isuflicient heat to cause the transformation of the coating into the infusible product as aforesaid, and at the same time the trans from the matrix to the from thematrix, and pressing the coated blank thus formed into a record Jnold with .suflicient application of heat to c ause the which consists in coating ablank mark sound record to be formed on the coating of the blank, substantially as described. .3. ,The process of molding sound records with ingredients which react upon applica tion of heat to: form a final hardened phenolic condensation product which is sufliciently plastic when heated to take a record impression, drying'the' coating, pressing a a blank thus formed into a record mold with sufiicient application of heat to cause the sound record to be formed on the coating of. the blank, substantially as described.

- 4. The process-of molding sound records and other objects which consists in forming upon a blank matrix a coating of substances including a solid solvent plasticity agent, which coating is adapted tobe transformed chemically by .heat into hardened phenolic cgndensation product which becomes sufli clently plastic on subsequent-application of heat to receive an impression, drying the coating, pressing a blank into contact with the coating with application of suflicient heat to cause a transformation of the coating into the hardened product as aforesaid and at the same time the transfer of the coat- I A from the matrix .to the blank,'withdrawon the coating of the blank, substantially as ing' 'the coated blank from-the matrix, and

iii-The process of molding soundrecords and'other objects whichconsists informing :upon a blank matrix a'coating of substances including a solid solventplastiity agent,

' which coating'is adapted to-be transformed chemically by heat intohardenedphenolic condensation product which becomes sulficiently plastic on subsequent application of heat to receive an impression, g the coating, pressing a blank into contact with the coatlng with application of suiiicient heat'to cause a transformation of the coatmg into the hardened product as aforesaid and at the same time the transfer of the coating from the matrix to the blank, and withdrawing the coated blank from the matrix, substantiallyas described. Y b

This specification signed andwitnessed this 1st, day of November-1910.

a JONAS W.AYLSWORTH. Witnesses:

.Drnn SMITH,"

ANNA R. KLEHM;

- It is hereby certified that in Letters Patent No. 1,146,390, granted July 13, 1915, upon the application of Jones W. Aylsworth, of East Orange, New Jersey,

--for an improvement in Methods of Molding Sound-Records and; Other Objects,

errors. appear in the printed specification requiring correction as follows: Page 1,

linev57, for the word v beznol read benzol; same page, line 62, after the date] February-11, 1910, insert the Words and numerals and upon which U. S. Patent No. 1,098,608, has been granted, same page, lines 64-65 strike out the comma, andthe words and numera and upon which U. S. Patent No. 1,098,608, has been granted, and line 64, after the word to insert a period; and that the said Letters Patent should be read with these corrections therein that the same may conform to the record of the case in the Patent Office.

Signed and sealed this 28th day of September, A. 1)., 1915.

[SEAL] 'J. T.. NEWTON,

' Acting Commissioner of Patents. 

